Antimicrobial coating for building panel

ABSTRACT

In general, the present invention is directed to a building panel, such as a gypsum board, comprising a core having a first side and a second side opposing the first side and at least one facing material having a coating comprising at least one fungicide, at least one polymeric binder, and at least one pigment. The panel satisfies at least one of the following: the board exhibits a rating of 2 or less when tested in accordance to ASTM G21-15 or the board exhibits a rating of at least 8 when tested in accordance to ASTM D3273-16. The panel may also exhibit at least a Level 3 finish.

CROSS-REFERENCE TO RELATED APPLICATION

The present application is a continuation of U.S. patent applicationSer. No. 16/656,828 having a filing date of Oct. 18, 2019 which claimsfiling benefit of U.S. Provisional Patent Application No. 62/747,688having a filing date of Oct. 19, 2018, and which are both incorporatedherein by reference in their entirety.

BACKGROUND OF THE INVENTION

Generally, finishing for gypsum board is characterized by having acertain level of finishing. For better finishes, typically suchfinishing steps can be quite labor-intensive, for example to provide asmooth final wall appearance. In addition, in certain instances, it isdesired to provide antimicrobial, such as mold and mildew, resistance tosuch gypsum boards. Typically, antimicrobial additives for providingsuch resistance are either included in the gypsum core or the matrix ofthe facing material when the facing material is manufactured.

As a result, there is a need to provide an improved coating, facingmaterial, and corresponding gypsum board that provide antimicrobialresistance as well as an improved appearance that may not be aslabor-intensive as traditional gypsum board.

SUMMARY OF THE INVENTION

In accordance with one embodiment of the present invention, a gypsumboard is disclosed. The gypsum board comprises a gypsum core having afirst side and a second side opposing the first side and at least onefacing material having a coating comprising at least one fungicide, atleast one polymeric binder, and at least one pigment. The board exhibitsat least a Level 3 finish. The board satisfies at least one of thefollowing: the board exhibits a rating of 2 or less when tested inaccordance to ASTM G21-15 or the board exhibits a rating of at least 8when tested in accordance to ASTM D3273-16.

In accordance with another embodiment of the present invention, a methodof making a gypsum board is disclosed. The method comprises providing afirst facing material, depositing a gypsum slurry onto the first facingmaterial, providing a second facing material onto the gypsum slurry, andwherein at least one of the first facing material and the second facingmaterial includes a coating comprising at least one fungicide, at leastone polymeric binder, and at least one pigment. The board exhibits atleast a Level 3 finish. The board satisfies at least one of thefollowing: the board exhibits a rating of 2 or less when tested inaccordance to ASTM G21-15 or the board exhibits a rating of at least 8when tested in accordance to ASTM D3273-16.

In accordance with another embodiment of the present invention, abuilding panel is disclosed. The building panel comprises a cementitiouscore having a first side and a second side opposing the first side andat least one facing material having a coating comprising at least onefungicide, at least one polymeric binder, and at least one pigment. Thepanel satisfies at least one of the following: the panel exhibits arating of 2 or less when tested in accordance to ASTM G21-15 or thepanel exhibits a rating of at least 8 when tested in accordance to ASTMD3273-16.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

It is to be understood by one skilled in the art that the presentdisclosure is a description of exemplary embodiments only, and is notintended as limiting the broader aspects of the present subject matter,which broader aspects are embodied in the exemplary constructions.

Generally, the present disclosure is directed to an antimicrobialcoating for a facing material, in particular a facing material for abuilding panel. The building panel may be a gypsum board or a cementboard. The coating includes at least one fungicide, at least onepolymeric binder, and at least one pigment. By employing a coating asdisclosed herein, the present inventors have discovered variousadvantages.

For instance, the present inventors have discovered that a boardcontaining a coating as disclosed herein can pass various antimicrobialtests. In particular, the panel, such as the gypsum board, containingthe facing material as coated herein can pass ASTM G21-15 entitled“Standard Practice for Determining Resistance of Synthetic PolymericMaterials to Fungi,” which is incorporated herein by reference in itsentirety. Such test utilizes the following fungi in the test:Aspergillus brasiliensis, Penicillium funiculosum, Chaetomium globosum,Trichoderma virens, and Aureobasidium pullulans. According to this test,the panel, such as the gypsum board, may have a rating of 2 or less,such as a rating of 1 or less (less than 10% coverage—trace of growth),such as a rating of 0, which indicates no growth according to thestandards of this test. Similarly, a coated facing material as disclosedherein would also pass ASTM G21-15 and exhibit a rating of 0.Furthermore, the coating formulation as disclosed herein could also becharacterized as providing a rating of 0 according to ASTM G21-15 whenapplied to a facing material as disclosed herein. In addition to suchtest, the panel, such as the gypsum board, coated facing material,and/or coating formulation when applied to a facing material may alsopass ASTM D3273-16. For instance, when tested according to ASTMD3273-16, the board may exhibit a rating of at least 8, such as at least9, such as 10. Generally, ASTM D3273-16 is less stringent than ASTMG21-15. Furthermore, regardless of the specific test utilized, thegrowth as determined by either test may be 20% or less, such as 15% orless, such as 10% or less, such as 5% or less.

In addition to the aforementioned antimicrobial effectiveness, thepresent inventors have discovered that the facing material and board mayexhibit a certain level finish. For instance, the board may exhibit atleast a Level 3 finish, such as at least a Level 4 finish, such as atleast a Level 5 finish. Such finishes, including a Level 5 finish, aredefined by ASTM C840-17a entitled “Standard Specification forApplication and Finishing of Gypsum Board,” which is incorporated hereinby reference in its entirety,” in particular section 24.6.6.1. Suchfinishes, including a Level 5 finish, may also be defined by GA-214-2015entitled “Recommended Levels of Finish for Gypsum Board, Glass Mat andFiber-Reinforced Gypsum Panels,” which is incorporated herein byreference in its entirety.

In addition to the above, the gypsum board as disclosed herein may alsosatisfy the standards according to ASTM C1396/C1396M-17 entitled“Standard Specification for Gypsum Board,” which is incorporated hereinby reference in its entirety. Furthermore, the coated facing material asdisclosed herein may also be characterized as satisfying the standardsof ASTM C1396/C1396M-17 when provided on a gypsum core for a gypsumboard as disclosed herein. In addition, the coating formulation asdisclosed herein may also be characterized as satisfying the standardsof ASTM C1396/C1396M-17 when applied to a facing material and on agypsum core for a gypsum board as disclosed herein.

The panel, such as the gypsum board, as disclosed herein may alsoexhibit improved abrasion. For instance, the panel, such as the gypsumboard, may exhibit a rating of at least 2, such as at least 3 whentested according to ASTM C1629/C1629M-15 entitled “StandardClassification for Abuse-Resistance Nondecorated Interior Gypsum PanelProducts and Fiber-Reinforced Cement Panels,” which is incorporatedherein by reference in its entirety. Furthermore, the coated facingmaterial as disclosed herein may also be characterized as satisfying theaforementioned ratings of ASTM C1629/C1629M-15 when provided on a gypsumcore for a gypsum board as disclosed herein. In addition, the coatingformulation as disclosed herein may also be characterized as satisfyingthe aforementioned ratings of ASTM C1629/C1629M-15 when applied to afacing material and on a core of a panel, such as a gypsum core for agypsum board, as disclosed herein. For instance, the board may have amaximum surface abrasion resistance of 1.5 mm, such as 1.25 mm, such as1 mm, such as 0.75 mm, such as 0.5 mm, such as 0.4 mm, such as 0.3 mm.The board may have a maximum indentation of 2.5 mm, such as 2 mm, suchas 1.5 mm, such as 1.3 mm. The board may have a minimum soft body impactvalue of of 265 J, such as 300 J, such as 325 J, such as 350 J, such as375 J, such as 400 J, such as 408 J. The board may have a minimum hardbody impact value of 136 J, such as 150 J, such as 175 J, such as 200 J,such as 204 J.

Furthermore, the panel, such as the gypsum board, as disclosed hereinmay also exhibit a recommended flame spread or smoke developed rating.For instance, such rating may be 0 according to ASTM E84-16 entitled“Standard Test Method for Surface Burning Characteristics of BuildingMaterials,” which is incorporated herein by reference in its entirety.Furthermore, the coated facing material as disclosed herein may also becharacterized as satisfying the aforementioned ratings of ASTM E84-16when provided on a core of a panel, such as a gypsum core for a gypsumboard, as disclosed herein. In addition, the coating formulation asdisclosed herein may also be characterized as satisfying theaforementioned ratings of ASTM E84-16 when applied to a facing materialand on a core of a panel, such as a gypsum core for a gypsum board, asdisclosed herein. In addition, the panel, such as the gypsum board, maysatisfy and pass a fire test as performed in accordance to ASTM E119.

Fungicide

As indicated above, the coating and coating formulation disclosed hereininclude at least one fungicide. The coating and coating formulation,however, may include more than one fungicide. For instance, in oneembodiment, the coating and coating formulation may include at least twofungicides, such as at least three fungicides

The fungicide may include various fungicides as generally known. Forinstance, the fungicide may include an azole. The fungicide may includea strobilurin. The fungicide may include fludioxonil. Also, thefungicide may include an isothiazolinone. Further, the fungicide mayinclude a pyrithione. In one embodiment, the fungicide may include anazole, a strobilurin, fludioxonil, an isothiazolinone, a pyrithione, ora mixture thereof. In another embodiment, the fungicide may include anazole, a strobilurin, fludioxonil, or a mixture thereof.

As indicated above, in one embodiment, the fungicide includes an azole.The azole may include any azole as generally known in the art. Forinstance, the azole may include thiabendazole, ketoconazole,fluconazole, itraconazole, voriconazole, posaconazole, ravuconazole,tebuconazole, fluconazole.bromuconazole, epoxiconazole, cyproconazole,flusilazole, metconazole, hexaconazole, difenoconazole, propiconazole,or a mixture thereof. In one embodiment, the fungicide may includethiabendazole, ketoconazole, fluconazole, metconazole, difenoconazole,propiconazole, or a mixture thereof. In one particular embodiment, thefungicide includes thiabendazole.

As indicated above, in one embodiment, the fungicide includes astrobilurin. The strobilurin may include any strobilurin as generallyknown in the art. For instance, the strobilurin may includeazoxystrobin, kresoxim-methyl, picoxystrobin, fluoxastrobin,oryzastrobin, dimoxystrobin, pyraclostrobin, trifloxystrobin, or amixture thereof. In one embodiment, the strobilurin includesazoxystrobin, azoxystrobin, trifloxystrobin, or a mixture thereof. Inone particular embodiment, the strobilurin includes azoxystrobin.

As indicated above, in one embodiment, the fungicide includesfludioxonil.

As indicated above, the fungicide may include at least one fungicide,such as at least two fungicides. In this regard, the fungicide mayinclude an azole and a strobilurin. For instance, the fungicide mayinclude thiabendazole and azoxystrobin. In one particular embodiment,the fungicide may include at least three fungicides. In this regard, thefungicides may include an azole, a strobilurin, and fludioxonil. Forinstance, the fungicides may include thiabendazole, azoxystrobin, andfludioxonil.

As indicated above, in one embodiment, the fungicide may include anisothiazolinone. The isothiazolinone may include any isothiazolinone asgenerally known in the art. For instance, the isothiazolinone mayinclude benzisothiazolinone, butylbenzisothiazolinone,octylisothiazolinone, dichlorooctylisothiazolinone,methylisothiazolinone, chloromethylisothiazolinone, or a mixturethereof. In one particular embodiment, the isothiazolinones may includea mixture of methylisothiazolinone and chloromethylisothiazolinone

As indicated above, in one embodiment, the fungicide may include apyrithione. The pyrithione may be any pyrithione as generally known inthe art. For instance, the pyrithione may be a zinc pyrithione, a sodiumpyrithione, a copper pyrithione, or a combination thereof. In oneembodiment, the pyrithione may include at least a zinc pyrithione. Inanother embodiment, the pyrithione may include at least a sodiumpyrithione. In a further embodiment, the pyrithione may include a zincpyrithione and a sodium pyrithione.

The fungicides may be present in an antimicrobially effective amount, inparticular a fungicidally effective amount or synergistic amount asdefined in U.S. Pat. No. 8,138,196, which is incorporated herein byreference in its entirety.

In particular, the fungicides may be present in the coating in an amountof 1 ppm or more, such as 5 ppm or more, such as 10 ppm or more, such as15 ppm or more, such as 20 ppm or more, such as 25 ppm or more, such as30 ppm or more, such as 40 ppm or more, such as 50 ppm or more, such as75 ppm or more, such as 100 ppm or more, such as 150 ppm or more, suchas 200 ppm or more, such as 300 ppm or more, such as 400 ppm or more,such as 500 ppm or more. The fungicides may be present in the coating inan amount of 10,000 ppm or less, such as 5,000 ppm or less, such as2,500 ppm or less, such as 2,000 ppm or less, such as 1,750 ppm or less,such as 1,500 ppm or less, such as 1,400 ppm or less, such as 1,300 ppmor less, such as 1,250 ppm or less, such as 1,200 ppm or less, such as1,100 ppm or less, such as 1,000 ppm or less, such as 900 ppm or less,such as 800 ppm or less, such as 600 ppm or less, such as 500 ppm orless, such as 400 ppm or less, such as 300 ppm or less, such as 200 ppmor less, such as 150 ppm or less, such as 100 ppm or less, such as 75ppm or less, such as 50 ppm or less, such as 40 ppm or less, such as 30ppm or less. In addition, such ppm concentrations may also be based onthe combined weight of the coating and facer. Further, such ppmconcentrations may be based on the combined weight of the coating andfacer per 1000 square feet. In addition, such ppm concentrations mayapply to a single fungicide or a combination of fungicides.

Pigment

As indicated above, the coating and coating formulation also includeadditional components. For instance, the coating and coating formulationmay also include a pigment, for example a white pigment. In general, awhite pigment may be referred to as one that gives a white color. In oneembodiment, the coating and coating formulation may include at least twopigments, a first pigment and a second pigment.

In one embodiment, the pigment includes a carbonate. For instance, thecarbonate may include an alkaline earth metal. In this regard, thecarbonate may include calcium carbonate, magnesium carbonate, or mixturethereof. In one particular embodiment, the carbonate includes at leastcalcium carbonate. In another embodiment, the carbonate includes calciumcarbonate and magnesium carbonate.

In another embodiment, the pigment may also include titanium dioxide.The titanium dioxide may be in the rutile or anatase crystalline form.In one embodiment, the titanium dioxide may be in the rutile crystallineform. In another embodiment, the titanium dioxide may be in the anatasecrystalline form.

The titanium dioxide pigment may be substantially pure titanium dioxideor may contain other metal oxides. For instance, the metal oxide mayinclude, but is not limited to, silica, alumina, or zirconia. In oneembodiment, the metal oxide includes at least two of silica, alumina, orzirconia. In one particular embodiment, the metal oxide includes atleast silica. In another embodiment, the metal oxide includes at leastalumina. In another particular embodiment, the metal oxide includessilica and alumina.

The titanium dioxide may be coated with the aforementioned metal oxide.The coating may be applied using various techniques known in the art,such as wet treatment techniques or oxidation with metal halides. In oneembodiment, the titanium dioxide may first be coated with silica andthen alumina.

In one embodiment, the pigment includes the aforementioned carbonate anda second pigment. For instance, the pigment may include a carbonate anda titanium dioxide. In particular, the pigment may include calciumcarbonate and titanium dioxide. In a further embodiment, the pigment mayinclude calcium carbonate, magnesium carbonate, and titanium dioxide.

The pigment may have a particular brightness as determined in accordancewith T534 om-76. In particular, the brightness may be at least 70%, suchas at least 75%, such as at least 80%, such as at least 85%, such as atleast 90%, such as at least 95%. The brightness may be 100% or less,such as 98% or less, such as 97% or less.

The pigment may also have a particular median size. For instance, themedian size may be 10 microns or less, such as 5 microns or less, suchas 4 microns or less, such as 3 microns or less, such as 2 microns orless, such as 1 micron or less, such as 0.75 microns or less, such as0.5 microns or less, such as 0.4 microns or less, such as 0.35 micronsor less. The median size may be 0.05 microns or more, such as 0.1microns or more, such as 0.15 microns or more, such as 0.2 microns ormore, such as 0.25 microns or more, such as 0.3 microns or more.

The pigment may be present in an amount of 5 wt. % or more, such as 10wt. % or more, such as 15 wt. % or more, such as 20 wt. % or more, suchas 25 wt. % or more, such as 30 wt. % or more, such as 40 wt. % or more,such as 50 wt. % or more, such as 55 wt. % or more, such as 60 wt. % ormore, such as 65 wt. % or more based on the weight of the coatingformulation. The pigment may be present in an amount of less than 100wt. %, such as 90 wt. % or less, such as 80 wt. % or less, such as 75wt. % or less, such as 70 wt. % or less, such as 65 wt. % or less, suchas 60 wt. % or less, such as 50 wt. % or less, such as 45 wt. % or less,such as 40 wt. % or less, such as 35 wt. % or less, such as 30 wt. % orless, such as 25 wt. % or less based on the weight of the coatingformulation. Such weight percentages may apply to a single pigment or acombination of pigments.

The pigment may be present in an amount of 5 wt. % or more, such as 10wt. % or more, such as 15 wt. % or more, such as 20 wt. % or more, suchas 25 wt. % or more, such as 30 wt. % or more, such as 40 wt. % or more,such as 50 wt. % or more, such as 55 wt. % or more, such as 60 wt. % ormore, such as 65 wt. % or more, such as 70 wt. % or more, such as 75 wt.% or more, such as 80 wt. % or more based on the solids content of thecoating formulation. The pigment may be present in an amount of lessthan 100 wt. %, such as 90 wt. % or less, such as 85 wt. % or less, suchas 80 wt. % or less, such as 75 wt. % or less, such as 70 wt. % or less,such as 65 wt. % or less, such as 60 wt. % or less, such as 50 wt. % orless, such as 45 wt. % or less, such as 40 wt. % or less, such as 35 wt.% or less, such as 30 wt. % or less, such as 25 wt. % or less based onthe solids content of the coating formulation. Such weight percentagesmay also apply based on the weight of the dried coating. In addition,such weight percentages may apply to a single pigment or a combinationof pigments.

Further, the aforementioned metal oxide may be present in an amount of0.1 wt. % or more, such as 0.25 wt. % or more, such as 0.5 wt. % ormore, such as 1 wt. % or more, such as 1.5 wt. % or more, such as 2 wt.% or more, such as 3 wt. % or more, such as 4 wt. % or more, such as 5wt. % or more based on the weight of the titanium dioxide. The metaloxide may be present in an amount of 10 wt. % or less, such as 8 wt. %or less, such as 7 wt. % or less, such as 6 wt. % or less, such as 5 wt.% or less, such as 4.5 wt. % or less, such as 4 wt. % or less, such as3.5 wt. % or less, such as 2 wt. % or less, such as 1.5 wt. % or lessbased on the weight of the titanium dioxide. Such weight percentages mayapply to a single metal oxide or a combination of metal oxides.

In addition, the metal oxide may be present in an amount of 0.1 wt. % ormore, such as 0.2 wt. % or more, such as 0.3 wt. % or more, such as 0.5wt. % or more, such as 0.7 wt. % or more, such as 0.75 wt. % or more,such as 1 wt. % or more, such as 1.1 wt. % or more, such as 1.2 wt. % ormore, such as 1.5 wt. % or more, such as 1.75 wt. % or more, such as 2wt. % or more based on the weight of the coating formulation. The metaloxide may be present in an amount of 10 wt. % or less, such as 8 wt. %or less, such as 5 wt. % or less, such as 4 wt. % or less, such as 3 wt.% or less, such as 2.5 wt. % or less, such as 2.25 wt. % or less, suchas 2 wt. % or less, such as 1.75 wt. % or less, such as 1.5 wt. % orless, such as 1.25 wt. % or less, such as 1 wt. % or less, such as 0.75wt. % or less, such as 0.5 wt. % or less based on the weight of thecoating formulation. Such weight percentages may apply to a single metaloxide or a combination of metal oxides.

In addition, the metal oxide may be present in an amount of 0.1 wt. % ormore, such as 0.2 wt. % or more, such as 0.5 wt. % or more, such as 0.75wt. % or more, such as 1 wt. % or more, such as 1.2 wt. % or more, suchas 1.5 wt. % or more, such as 1.7 wt. % or more, such as 2 wt. % ormore, such as 2.5 wt. % or more based on the solids content of thecoating formulation. The metal oxide may be present in an amount of 10wt. % or less, such as 8 wt. % or less, such as 5 wt. % or less, such as4 wt. % or less, such as 3 wt. % or less, such as 2.5 wt. % or less,such as 2.25 wt. % or less, such as 2 wt. % or less, such as 1.75 wt. %or less, such as 1.5 wt. % or less, such as 1.25 wt. % or less, such as1 wt. % or less, such as 0.75 wt. % or less, such as 0.5 wt. % or lessbased on the solids content of the coating formulation. Such weightpercentages may also apply based on the weight of the dried coating. Inaddition, such weight percentages may apply to a single metal oxide or acombination of metal oxides.

Binder

As indicated above, the coating and coating formulation may also includeadditional components. For instance, the coating and coating formulationmay also include a binder. For instance, in one embodiment, the bindermay be a polymeric binder. The binder may be any binder as generallyknown in the art. The binder may include a vinyl acetate polymer orcopolymer, an acrylic polymer or copolymer, a styrene polymer orcopolymer, a vinyl acrylic polymer or copolymer, a cellulose, a starch,etc. or a mixture thereof.

In particular, the binder may include an acrylic (or acrylate) polymeror copolymer, a styrene acrylic copolymer, a styrene butadienecopolymer, a vinyl acrylic copolymer, or a mixture thereof. Suitableunsaturated monomers for use in forming the polymer are generallyethylenically unsaturated monomers and include vinylaromatic compounds(e.g. styrene, α-methylstyrene, o-chlorostyrene, and vinyltoluenes);1,2-butadiene (i.e. butadiene); conjugated dienes (e.g. 1,3-butadieneand isoprene); α,β-monoethylenically unsaturated mono- and dicarboxylicacids or anhydrides thereof (e.g. acrylic acid, methacrylic acid,crotonic acid, dimethacrylic acid, ethylacrylic acid, allylacetic acid,vinylacetic acid maleic acid, fumaric acid, itaconic acid, mesaconicacid, methylenemalonic acid, citraconic acid, maleic anhydride, itaconicanhydride, and methylmalonic anhydride); esters of α,β-monoethylenicallyunsaturated mono- and dicarboxylic acids having 3 to 6 carbon atoms withalkanols having 1 to 12 carbon atoms (e.g. esters of acrylic acid,methacrylic acid, maleic acid, fumaric acid, or itaconic acid, withC1-C12, C1-C8, or C1-C4 alkanols such as ethyl, n-butyl, isobutyl and2-ethylhexyl acrylates and methacrylates, dimethyl maleate and n-butylmaleate); acrylamides and alkyl-substituted acrylamides (e.g.(meth)acrylamide, N-tert-butylacrylamide, and N-methyl(meth)acrylamide);(meth)acrylonitrile; vinyl and vinylidene halides (e.g. vinyl chlorideand vinylidene chloride); vinyl esters of C1-C18 mono- or dicarboxylicacids (e.g. vinyl acetate, vinyl propionate, vinyl n-butyrate, vinyllaurate and vinyl stearate); C1-C4 hydroxyalkyl esters of C3-C6 mono- ordicarboxylic acids, especially of acrylic acid, methacrylic acid ormaleic acid, or their derivatives alkoxylated with from 2 to 50 moles ofethylene oxide, propylene oxide, butylene oxide or mixtures thereof, oresters of these acids with C1-C18 alcohols alkoxylated with from 2 to 50mol of ethylene oxide, propylene oxide, butylene oxide or mixturesthereof (e.g. hydroxyethyl(meth)acrylate, hydroxypropyl(meth)acrylate,and methylpolyglycol acrylate); and monomers containing glycidyl groups(e.g. glycidyl methacrylate).

Additional monomers that can be used include linear 1-olefins,branched-chain 1-olefins or cyclic olefins (e.g., ethene, propene,butene, isobutene, pentene, cyclopentene, hexene, and cyclohexene);vinyl and allyl alkyl ethers having 1 to 40 carbon atoms in the alkylradical, wherein the alkyl radical can possibly carry furthersubstituents such as a hydroxyl group, an amino or dialkylamino group,or one or more alkoxylated groups (e.g. methyl vinyl ether, ethyl vinylether, propyl vinyl ether, isobutyl vinyl ether, 2-ethylhexyl vinylether, vinyl cyclohexyl ether, vinyl 4-hydroxybutyl ether, decyl vinylether, dodecyl vinyl ether, octadecyl vinyl ether, 2-(diethylamino)ethylvinyl ether, 2-(di-n-butylamino)ethyl vinyl ether, methyldiglycol vinylether, and the corresponding allyl ethers); sulfo-functional monomers(e.g. allylsulfonic acid, methallylsulfonic acid, styrenesulfonate,vinylsulfonic acid, allyloxybenzenesulfonic acid,2-acrylamido-2-methylpropanesulfonic acid, and their correspondingalkali metal or ammonium salts, sulfopropyl acrylate and sulfopropylmethacrylate); vinylphosphonic acid, dimethyl vinylphosphonate, andother phosphorus monomers; alkylaminoalkyl(meth)acrylates oralkylaminoalkyl(meth)acrylamides or quaternization products thereof(e.g. 2-(N,N-dimethylamino)ethyl(meth)acrylate,3-(N,N-dimethylamino)propyl(meth)acrylate,2-(N,N,N-trimethylammonium)ethyl(meth)acrylate chloride,2-dimethylaminoethyl(meth)acrylamide,3-dimethylaminopropyl(meth)acrylamide, and3-trimethylammoniumpropyl(meth)acrylamide chloride); allyl esters ofC1-C30 monocarboxylic acids; N-Vinyl compounds (e.g. N-vinylformamide,N-vinyl-N-methylformamide, N-vinylpyrrolidone, N-vinylimidazole,1-vinyl-2-methylimidazole, 1-vinyl-2-methylimidazoline,N-vinylcaprolactam, vinylcarbazole, 2-vinylpyridine, and4-vinylpyridine); monomers containing 1,3-diketo groups (e.g.acetoacetoxyethyl(meth)acrylate or diacetonacrylamide; monomerscontaining urea groups (e.g. ureidoethyl(meth)acrylate,acrylamidoglycolic acid, and methacrylamidoglycolate methyl ether); andmonomers containing silyl groups (e.g. trimethoxysilylpropylmethacrylate).

In one embodiment, the binder includes at least a styrene butadienecopolymer. In particular, the styrene butadiene copolymer may be amodified copolymer. For instance, the styrene butadiene copolymer may bea carboxylated styrene butadiene copolymer. In another embodiment, thebinder includes at least an acrylic polymer. In particular, the bindermay include a metal salt of an acrylic polymer, such as an alkali metalsalt of an acrylic polymer. For instance, the alkali metal may includesodium. In a further embodiment, the binder includes both of theaforementioned styrene butadiene copolymer and acrylic polymer.

As indicated above, the binder may include a vinyl acetate polymer orcopolymer. In this regard, the binder may include a polyvinyl acetate,an ethylene vinyl acetate, etc., or a mixture thereof.

As indicated above, the binder may include a cellulose, such as acellulose ether. The cellulose ether may include a hydroxyethylcellulose, a carboxymethyl cellulose, a hydroxypropyl cellulose, etc.,or a mixture thereof.

The binder may be present in an amount of 0.1 wt. % or more, such as 0.2wt. % or more, such as 0.3 wt. % or more, such as 0.5 wt. % or more,such as 0.8 wt. % or more, such as 1 wt. % or more, such as 2 wt. % ormore, such as 3 wt. % or more, such as 5 wt. % or more, such as 7 wt. %or more, such as 8 wt. % or more, such as 10 wt. % or more, such as 15wt. % or more, such as 20 wt. % or more based on the weight of thecoating formulation. The binder may be present in an amount of less than100 wt. %, such as 90 wt. % or less, such as 80 wt. % or less, such as70 wt. % or less, such as 60 wt. % or less, such as 50 wt. % or less,such as 40 wt. % or less, such as 30 wt. % or less, such as 20 wt. % orless, such as 15 wt. % or less, such as 10 wt. % or less, such as 9 wt.% or less, such as 8 wt. % or less, such as 5 wt. % or less, such as 3wt. % or less, such as 2 wt. % or less, such as 1 wt. % or less, such as0.9 wt. % or less, such as 0.7 wt. % or less, such as 0.5 wt. % or lessbased on the weight of the coating formulation. Such weight percentagesmay apply to a single binder or a combination of binders.

The binder may be present in an amount of 0.1 wt. % or more, such as 0.2wt. % or more, such as 0.3 wt. % or more, such as 0.5 wt. % or more,such as 0.8 wt. % or more, such as 1 wt. % or more, such as 2 wt. % ormore, such as 3 wt. % or more, such as 5 wt. % or more, such as 7 wt. %or more, such as 8 wt. % or more, such as 10 wt. % or more, such as 15wt. % or more, such as 20 wt. % or more based on the solids content ofthe coating formulation. The binder may be present in an amount of lessthan 100 wt. %, such as 90 wt. % or less, such as 80 wt. % or less, suchas 70 wt. % or less, such as 60 wt. % or less, such as 50 wt. % or less,such as 40 wt. % or less, such as 30 wt. % or less, such as 20 wt. % orless, such as 15 wt. % or less, such as 10 wt. % or less, such as 9 wt.% or less, such as 8 wt. % or less, such as 5 wt. % or less, such as 3wt. % or less, such as 2 wt. % or less, such as 1 wt. % or less, such as0.9 wt. % or less, such as 0.7 wt. % or less, such as 0.5 wt. % or lessbased on the solids content of the coating formulation. Such weightpercentages may also apply based on the weight of the dried coating. Inaddition, such weight percentages may apply to a single binder or acombination of binders.

Wax

As indicated above, the coating and coating formulation may also includeadditional components. For instance, the coating and coating formulationmay also include a wax. The wax may be any wax as generally known in theart. In general, the wax may be a solid at room temperature but may meltor soften when heated, such as at a temperature of 25° C. or more, suchas 30° C. or more, such as 40° C. or more, such as 50° C. or more, suchas 75° C. or more, such as 100° C. or more, such as 125° C. or more.Such temperature may also be referred to as the softening point of thewax.

The wax may be a natural wax, a synthetic wax or a combination thereof.The waxy may include animal waxes (e.g., beeswax, shlac wax, wool wax),vegetable waxes (e.g., bayberry wax, carnauba wax, castor wax, Jojobaoil wax, rice bran wax, soy wax), mineral waxes (e.g., montan wax, peatwax), petroleum waxes (e.g., paraffin wax, microcrystalline wax),synthetic waxes (e.g., polyolefin wax, polytetrafluoroethylene wax,stearamide wax, polymerized α-olefin wax, substituted amide waxes). Thewaxes may include any combination of the aforementioned waxes.

In one embodiment, the wax includes a polyolefin wax. The polyolefin waxmay be a homopolymer wax or a copolymer wax. The polyolefin wax may be amodified wax or an unmodified wax. The polyolefin wax may be apolyethylene wax, a polypropylene wax, or a mixture thereof. In oneembodiment, the wax includes at least a polyethylene wax, such as ahomopolymer polyethylene wax, a copolymer polyethylene wax, or a mixturethereof. In another embodiment, the wax includes a polypropylene wax,such as a homopolymer polypropylene wax, a copolymer polypropylene wax,or a mixture thereof.

In general, the wax may be branched or linear. Also, the way may havelow crystallinity (e.g., less than 20%), moderate crystallinity (e.g.,20% to 40%), or high crystallinity (e.g., greater than 40%). The wax mayhave a weight average molecular weight of 500 g/mol or more, such as1,000 g/mol or more, such as 1,500 g/mol or more, such as 2,000 g/mol ormore, such as 3,000 g/mol or more, such as 4,000 g/mol or more, such as5,000 g/mol or more. The way may have a weight average molecular weightof 50,000 g/mol or less, such as 40,000 g/mol or less, such as 30,000g/mol or less, such as 20,000 g/mol or less, such as 15,000 g/mol orless, such as 13,000 g/mol or less, such as 11,000 g/mol or less, suchas 10,000 g/mol or less, such as 8,000 g/mol or less. The wax may have apolydispersity of from about 1.0 to about 4.0, more preferably fromabout 1.0 to about 2.5 and most preferably from about 1.0 to about 1.5.

In addition, the wax may generally not form a stand-alone film.Furthermore, the wax may have a certain viscosity at 25° C. whendispersed in water. For instance, the viscosity may be 5 cps or more,such as 10 cps or more, such as 25 cps or more, such as 30 cps or more,such as 40 cps or more, such as 50 cps or more, such as 100 cps or more,such as 250 cps or more, such as 300 cps or more, such as 500 cps ormore, such as 1,000 cps or more. The viscosity may be 10,000 cps orless, such as 7,500 cps or less, such as 5,000 cps or less, such as2,500 cps or less, such as 2,000 cps or less, such as 1,500 cps or less,such as 1,000 cps or less, such as 750 cps or less, such as 500 cps orless, such as 400 cps or less, such as 300 cps or less, such as 200 cpsor less, such as 150 cps or less, such as 100 cps or less, such as 75cps or less, such as 50 cps or less, such as 40 cps or less. Suchviscosity may be measured using known techniques in the art. Forinstance, the viscosity may be measured using a Brookfield instrument ortest, such as a Brookfield rotational viscometer.

The wax may also have a certain average particle size. For instance, thewax may have particles having an average particle size of 0.1 microns ormore, such as 0.25 microns or more, such as 0.5 microns or more, such as0.75 microns or more, such as 1 micron or more, such as 2 microns ormore, such as 3 microns or more, such as 3.5 microns or more, such as 4microns or more. The wax may have particles having an average particlesize of 20 microns or less, such as 15 microns or less, such as 10microns or less, such as 8 microns or less, such as 7 microns or less,such as 6 microns or less, such as 5 microns or less, such as 4.5microns or less. Furthermore, all of the wax particles may have aparticle size of 30 microns or less, such as 25 microns or less, such as20 microns or less.

The wax may be present in the coating formulation in an amount of 0.001wt. % or more, such as 0.01 wt. % or more, such as 0.02 wt. % or more,such as 0.04 wt. % or more, such as 0.05 wt. % or more, such as 0.06 wt.% or more, such as 0.07 wt. % or more, such as 0.08 wt. % or more, suchas 0.01 wt. % or more. The wax may be present in the coating formulationin an amount of 5 wt. % or less, such as 4 wt. % or less, such as 3 wt.% or less, such as 2 wt. % or less, such as 1.5 wt. % or less, such as 1wt. % or less, such as 0.75 wt. % or less, such as 0.5 wt. % or less,such as 0.4 wt. % or less, such as 0.3 wt. % or less, such as 0.2 wt. %or less, such as 0.15 wt. % or less, such as 0.1 wt. % or less. Suchweight percentages may apply to a single wax or a combination of waxes.

The wax may be present in the coating formulation in an amount of 0.001wt. % or more, such as 0.01 wt. % or more, such as 0.02 wt. % or more,such as 0.04 wt. % or more, such as 0.05 wt. % or more, such as 0.06 wt.% or more, such as 0.07 wt. % or more, such as 0.08 wt. % or more, suchas 0.01 wt. % or more based on the solids content of the coatingformulation. The wax may be present in the coating formulation in anamount of 5 wt. % or less, such as 4 wt. % or less, such as 3 wt. % orless, such as 2 wt. % or less, such as 1.5 wt. % or less, such as 1 wt.% or less, such as 0.75 wt. % or less, such as 0.5 wt. % or less, suchas 0.4 wt. % or less, such as 0.3 wt. % or less, such as 0.2 wt. % orless, such as 0.15 wt. % or less, such as 0.1 wt. % or less based on thesolids content of the coating formulation. Such weight percentages mayalso apply based on the weight of the dried coating. In addition, suchweight percentages may apply to a single wax or a combination of waxes.

Wetting Agent

As indicated above, the coating and coating formulation may also includeadditional components. For instance, the coating and coating formulationmay also include a wetting agent. The wetting agent may be a surfactant.The surfactant may be an anionic surfactant, a cationic surfactant, anonionic surfactant, or any mixtures thereof. In one particularembodiment, the surfactant may be an anionic surfactant. In anotherparticular embodiment, the surfactant may be a nonionic surfactant. In afurther embodiment, the surfactant may be a cationic surfactant.

As indicated above, in one embodiment, the surfactant may include ananionic surfactant. In general, anionic surfactants include those havingone or more negatively charged functional groups. For instance, theanionic surfactant includes alkali metal or ammonium salts of alkyl,aryl or alkylaryl sulfonates, sulfates, phosphates. For instance, theanionic surfactant may include sodium lauryl sulfate, sodium octylphenolglycolether sulfate, sodium dodecylbenzene sulfonate, sodiumlauryldiglycol sulfate, ammonium tritertiarybutyl phenol and penta- andocta-glycol sulfonates, sulfosuccinate salts such as disodiumethoxylated nonylphenol half ester of sulfosuccinic acid, disodiumn-octyldecyl sulfosuccinate, sodium dioctyl sulfosuccinate, and mixturesthereof. Other examples include a C₈-C₂₂ alkyl fatty acid salt of analkali metal, alkaline earth metal, ammonium, alkyl substitutedammonium, for example, isopropylamine salt, or alkanolammonium salt, aC₈-C₂₂ alkyl fatty acid ester, a C₈-C₂₂ alkyl fatty acid ester salt, andalkyl ether carboxylates.

In one particular embodiment, the anionic surfactant includes awater-soluble salt, particularly an alkali metal salt, of an organicsulfur reaction product having in their molecular structure an alkylradical containing from about 8 to 22 carbon atoms and a radicalselected from the group consisting of sulfonic and sulfuric acid esterradicals. Organic sulfur based anionic surfactants include the salts ofC₁₀-C₁₆ alkylbenzene sulfonates, C₁₀-C₂₂ alkane sulfonates, C₁₀-C₂₂alkyl ether sulfates, C₁₀-C₂₂ alkyl sulfates, C₄-C₁₀dialkylsulfosuccinates, C₁₀-C₂₂ acyl isothionates, alkyl diphenyloxidesulfonates, alkyl naphthalene sulfonates, and 2-acetamido hexadecanesulfonates. Organic phosphate based anionic surfactants include organicphosphate esters such as complex mono- or diester phosphates ofhydroxyl-terminated alkoxide condensates, or salts thereof. Included inthe organic phosphate esters are phosphate ester derivatives ofpolyoxyalkylated alkylaryl phosphate esters, of ethoxylated linearalcohols and ethoxylates of phenol. Particular examples of anionicsurfactants include a polyoxyethylene alkyl ether sulfuric ester salt, apolyoxyethylene alkylphenyl ether sulfuric ester salt, polyoxyethylenestyrenated alkylether ammonium sulfate, polyoxymethylene alkylphenylether ammonium sulfate, and the like, and mixtures thereof. Forinstance, the anionic surfactant may include a polyoxyethylene alkylether sulfuric ester salt, a polyoxyethylene alkylphenyl ether sulfuricester salt, or a mixture thereof.

As indicated above, in one embodiment, the surfactant may include anon-ionic surfactant. The non-ionic surfactant may be generally as knownin the art. Generally, nonionic surfactants include, but are not limitedto, amine oxides, fatty acid amides, ethoxylates (e.g., ethoxylatedfatty acids, ethoxylated fatty alcohols, etc.), block copolymers ofpolyethylene glycol and polypropylene glycol, glycerol alkyl esters,alkyl polyglucosides, polyoxyethylene glycol octylphenol ethers,sorbitan alkyl esters, polyoxyethylene glycol sorbitan alkyl esters, andmixtures thereof. For instance, the non-ionic surfactant may include apolyethylene oxide condensate of an alkyl phenol (e.g., the condensationproduct of an alkyl phenol having an alkyl group containing from 6 to 12carbon atoms in either a straight chain or branched chain configuration,with ethylene oxide (e.g., present in amounts equal to 1 to 40 moles)).The alkyl substituent may be derived, for example, from polymerizedpropylene, di-isobutylene, octane or nonene. Other examples includedodecylphenol condensed with 12 moles of ethylene oxide per mole ofphenol; dinonylphenol condensed with 5 moles of ethylene oxide per moleof phenol; nonylphenol condensed with 9 moles of ethylene oxide per moleof nonylphenol and di-iso-octylphenol condensed with 5 moles of ethyleneoxide. The non-ionic surfactant may be a condensation product of aprimary or secondary aliphatic alcohol having from 8 to 24 carbon atoms,in either straight chain or branched chain configuration, with from 1 toabout 40 moles of alkylene oxide per mole of alcohol. The non-ionicsurfactant may include a compound formed by condensing ethylene oxidewith a hydrophobic base formed by the condensation of propylene oxidewith propylene glycol (e.g., Pluronics).

As indicated above, in one embodiment, the surfactant may include acationic surfactant. Examples of the cationic surfactant may includewater-soluble quaternary ammonium compounds, polyammonium salts, apolyoxyethylene alkylamine and the like.

Such wetting agent may be present in the coating formulation in anamount of 0.01 wt. % or more, such as 0.01 wt. % or more, such as 0.05wt. % or more, such as 0.1 wt. % or more, such as 0.15 wt. % or more,such as 0.2 wt. % or more, such as 0.25 wt. % or more, such as 0.3 wt. %or more, such as 0.5 wt. % or more, such as 0.75 wt. % or more, such as1 wt. % or more. The wetting agent may be present in the coatingformulation in an amount of 5 wt. % or less, such as 4 wt. % or less,such as 3 wt. % or less, such as 2 wt. % or less, such as 1.5 wt. % orless, such as 1 wt. % or less, such as 0.75 wt. % or less, such as 0.5wt. % or less, such as 0.4 wt. % or less, such as 0.35 wt. % or less,such as 0.3 wt. % or less, such as 0.25 wt. % or less, such as 0.2 wt. %or less, such as 0.15 wt. % or less. Such weight percentages may applyto a single wetting agent or a combination of wetting agents.

Such wetting agent may be present in the coating formulation in anamount of 0.01 wt. % or more, such as 0.01 wt. % or more, such as 0.05wt. % or more, such as 0.1 wt. % or more, such as 0.15 wt. % or more,such as 0.2 wt. % or more, such as 0.25 wt. % or more, such as 0.3 wt. %or more, such as 0.5 wt. % or more, such as 0.75 wt. % or more, such as1 wt. % or more based on the solids content of the coating formulations.The wetting agent may be present in the coating formulation in an amountof 5 wt. % or less, such as 4 wt. % or less, such as 3 wt. % or less,such as 2 wt. % or less, such as 1.5 wt. % or less, such as 1 wt. % orless, such as 0.75 wt. % or less, such as 0.5 wt. % or less, such as 0.4wt. % or less, such as 0.35 wt. % or less, such as 0.3 wt. % or less,such as 0.25 wt. % or less, such as 0.2 wt. % or less, such as 0.15 wt.% or less based on the solids content of the coating formulations. Suchweight percentages may also apply based on the weight of the driedcoating. In addition, such weight percentages may apply to a singlewetting agent or a combination of wetting agents.

Additional Components

The coating and coating formulation may also include additionalcomponents as generally known in the art. For instance, the coatingand/or coating formulation may include aggregates (e.g., silica, sand,mica, talc), preservatives, pH adjusters, moisture resistant additives(e.g., silicone), etc.

Such additional components may be present in the coating formulation inan amount of 0 wt. % or more, such as 0.01 wt. % or more, such as 0.05wt. % or more, such as 0.1 wt. % or more, such as 0.25 wt. % or more,such as 0.5 wt. % or more, such as 0.75 wt. % or more, such as 1 wt. %or more, such as 1.25 wt. % or more, such as 1.5 wt. % or more, such as2 wt. % or more. The additional components may be present in the coatingformulation in an amount of 10 wt. % or less, such as 8 wt. % or less,such as 6 wt. % or less, such as 5 wt. % or less, such as 4 wt. % orless, such as 3 wt. % or less, such as 2 wt. % or less, such as 1.5 wt.% or less, such as 1 wt. % or less, such as 0.75 wt. % or less, such as0.5 wt. % or less, such as 0.25 wt. % or less, such as 0.2 wt. % orless, such as 0.15 wt. % or less, such as 0.1 wt. % or less. Such weightpercentages may apply to a single additional component or a combinationof additional components.

Such additional components may be present in the coating formulation inan amount of 0 wt. % or more, such as 0.01 wt. % or more, such as 0.05wt. % or more, such as 0.1 wt. % or more, such as 0.25 wt. % or more,such as 0.5 wt. % or more, such as 0.75 wt. % or more, such as 1 wt. %or more, such as 1.25 wt. % or more, such as 1.5 wt. % or more, such as2 wt. % or more based on weight solids content of the coatingformulation. The additional components may be present in the coatingformulation in an amount of 10 wt. % or less, such as 8 wt. % or less,such as 6 wt. % or less, such as 5 wt. % or less, such as 4 wt. % orless, such as 3 wt. % or less, such as 2 wt. % or less, such as 1.5 wt.% or less, such as 1 wt. % or less, such as 0.75 wt. % or less, such as0.5 wt. % or less, such as 0.25 wt. % or less, such as 0.2 wt. % orless, such as 0.15 wt. % or less, such as 0.1 wt. % or less based onweight solids content of the coating formulation. Such weightpercentages may also apply based on the weight of the dried coating. Inaddition, such weight percentages may apply to a single additionalcomponent or a combination of additional components.

Coating Formulation

The present invention is also directed to a coating formulation. Thecoating formulation includes the aforementioned components. Forinstance, the coating formulation includes at least one fungicide and atleast one pigment. The coating formulation may also include at least onebinder. The coating formulation may also include at least one wax. Thecoating formulation may also include at least one wetting agent, such asa surfactant. However, the coating formulation may also include otheradditives as generally known in the art.

For instance, in one embodiment, the coating formulation may alsoinclude a carrier, in particular a liquid carrier. The carrier mayassist in delivering the components of the coating formulation to asubstrate. The liquid carrier may be any liquid carrier as generallyknown in the art. In one embodiment, the liquid carrier may be water.

The liquid carrier may be present in the coating formulation in anamount of 2 wt. % or more, such as 5 wt. % or more, such as 10 wt. % ormore, such as 15 wt. % or more, such as such as 20 wt. % or more, suchas 25 wt. % or more, such as 30 wt. % or more, such as 40 wt. % or more,such as 50 wt. % or more, such as 60 wt. % or more, such as 70 wt. % ormore, such as 80 wt. % or more. The liquid carrier may be present in thecoating formulation in an amount of less than 100 wt. %, such as 90 wt.% or less, such as 80 wt. % or less, such as 70 wt. % or less, such as60 wt. % or less, such as 50 wt. % or less, such as 40 wt. % or less,such as 30 wt. % or less.

The solids content of the coating formulation may be 5 wt. % or more,such as 10 wt. % or more, such as 20 wt. % or more, such as 30 wt. % ormore, such as 40 wt. % or more, such as 50 wt. % or more, such as 60 wt.% or more, such as 70 wt. % or more, such as 75 wt. % or more. Thesolids content of the coating formulation may be less than 100 wt. %,such as 90 wt. % or less, such as 80 wt. % or less, such as 75 wt. % orless, such as 60 wt. % or less, such as 50 wt. % or less, such as 40 wt.% or less.

In one embodiment, the coating formulation may be an alkaline pH. Forinstance, the coating formulation may have a pH of greater than 7, suchas 7.5 or more, such as 8 or more, such as 8.5 or more, such as 9 ormore. The pH may be less than 14, such as 13 or less, such as 12 orless, such as 10 or less, such as 9.5 or less, such as 9 or less.

Coating

As indicated herein, the coating is provided for a building panel, suchas a gypsum board or a cement board. In one embodiment, the buildingpanel comprises a gypsum board. In another embodiment, the buildingpanel comprises a cement board.

In general, the building panel includes a cementitious core having afirst side and a second side opposing the first side. The cementitiouscore may be a gypsum core or a cement core. The building panel alsoincludes a facing material on both sides, such as the major (or broad)surfaces (i.e., front surface and back surface or otherwise known asfront facing material and back facing material, respectively). Ingeneral, the composition of the cementitious core is not limited by thepresent invention and may include any components as generally known inthe art.

In particular, the gypsum board includes a gypsum core having a firstside and a second side opposing the first side. The gypsum board alsoincludes a facing material on both sides, such as the major (or broad)surfaces (i.e., front surface and back surface or otherwise known asfront facing material and back facing material, respectively). Ingeneral, the back facing material is on the surface of the gypsum corethat faces the interior of a wall assembly and the front facing materialis on the opposite surface. In addition, the composition of the gypsumcore is not limited by the present invention and may include anycomponents as generally known in the art.

Similarly, the cement board includes a cement core having a first sideand a second side opposing the first side. The cement board alsoincludes a facing material on both sides, such as the major (or broad)surfaces (i.e., front surface and back surface or otherwise known asfront facing material and back facing material, respectively). Ingeneral, the composition of the cement core is not limited by thepresent invention and may include any components as generally known inthe art.

Furthermore, the facing material is not limited by the presentinvention. For instance, the facing material may be paper, glass mat, orglass mesh. In one embodiment, both facing materials are paper. Inanother embodiment, both facing materials are glass mat. In a furtherembodiment, both facing materials are glass mesh. In a furtherembodiment, one facing material is paper while the other facing materialis glass, such as glass mat.

In one embodiment, the coating disclosed herein is provided on the frontfacing material. In another embodiment, the coating is provided on theback facing material. In a further embodiment, the coating is providedon a front facing material and a back facing material.

The coating can be applied using various methods known in the art. Forinstance, the coating can be applied by using techniques including, butnot limited to, spraying, rolling, or coating the coating formulationonto the facing material. However, it should be understood that othermethods as generally employed in the art may also be utilized.

The coating may be present on the facing material in an amount of atleast 1 pound/1000 square feet, such as at least 2 pounds/1000 squarefeet, such as at least 3 pounds/1000 square feet, such as at least 4pounds/1000 square feet, such as at least 5 pounds/1000 square feet,such as at least 6 pounds/1000 square feet. The coating may be presenton the facer in an amount of 15 pounds per 1000 square feet or less,such as 10 pounds per 1000 square feet or less, such as 9 pounds per1000 square feet or less, such as 8 pounds per 1000 square feet or less,such as 7 pounds per 1000 square feet or less, such as 6 pounds per 1000square feet or less.

In this regard, the coating formulation may be applied to the facingmaterial prior to forming the panel, such as the gypsum board. Forinstance, the facing material may be pre-coated. Alternatively, thecoating formulation may be applied to the facing material in-line duringproduction of the panel, such as the gypsum board. For instance, thecoating formulation may be applied to the facing material prior todeposition of the slurry, such as the gypsum slurry, such that thecoating formulation has sufficient time to dry. Alternatively, thecoating formulation may be applied after deposition of the slurry, suchas the gypsum slurry.

In this regard, the present invention is also directed to a method offorming a coated facing material. The method comprises applying thecoating formulation as disclosed herein to a facing material. The methodmay also include a step of drying the facing material to form thecoating. Such drying may be in the presence of air. Additionally, thedrying temperature may be 25° C. or more, such as 30° C. or more, suchas 35° C. or more, such as 40° C. or more, such as 50° C. or more.

Furthermore, the present invention is also directed to a method offorming a building panel, such as a gypsum board or a cement board. Themethod comprises a step of providing a first facing material, depositinga slurry, such as a gypsum slurry nor a cement slurry, onto the firstfacing material, and providing a second facing material on top of theslurry. In this regard, such method may form a “sandwich.” Furthermore,at least one of the first facing material or second facing materialincludes the coating as disclosed herein. The coating may be provided onthe surface of the facing material that is opposite the surface adjacentto the slurry or core. Thereafter, the slurry and core may set, theboard may be dried, and the board may be cut or sliced using standardtechniques as known in the art.

In the aforementioned, the coating may be provided to the facingmaterial prior to the providing steps as disclosed above. In thisregard, the facing material may be pre-coated. That is, the facingmaterial may be pre-coated off-line (i.e., in a different manufacturingline) and dried. The facing material may then be optionally rolled andplaced in-line for the providing step mentioned above. Alternatively,the facing material may be provided in-line and coated in-line prior tothe providing step mentioned above.

In another embodiment, the coating may be provided to the facingmaterial after the providing step as disclosed above. For instance, oncethe facing material is provided to the manufacturing process and theslurry, such as the gypsum slurry, is sandwiched, the coatingformulation may be applied as disclosed herein in order to provide thecoating on the facing material.

These and other modifications and variations of the present inventionmay be practiced by those of ordinary skill in the art, withoutdeparting from the spirit and scope of the present invention. Inaddition, it should be understood that aspects of the variousembodiments may be interchanged both in whole or in part. Furthermore,those of ordinary skill in the art will appreciate that the foregoingdescription is by way of example only, and is not intended to limit theinvention so further described in such appended claims.

What is claimed is:
 1. A wall assembly comprising: a gypsum boardcomprising a gypsum core having a first side and a second side opposingthe first side, at least one facing material having a coating comprisingat least one fungicide comprising at least one of an azole, astrobilurin, a fludioxonil, an isothiazolinone, a pyrithione, or amixture thereof, at least one polymeric binder, and at least onepigment, wherein the board exhibits at least a Level 3 finish, andwherein the board satisfies at least one of the following: the boardexhibits a rating of 2 or less when tested in accordance to ASTM G21-15,or the board exhibits a rating of at least 8 when tested in accordanceto ASTM D3273-16.
 2. The wall assembly of claim 1, wherein the boardexhibits a rating of 2 or less when tested in accordance to ASTM G21-15and a rating of at least 8 when tested in accordance to ASTM D3273-16.3. The wall assembly of claim 1, wherein the board exhibits a Level 5finish.
 4. The wall assembly of claim 1, wherein the board exhibits anabrasion rating of at least 2 when tested in accordance to ASTMC1629/C1629M-15.
 5. The wall assembly of claim 1, wherein the at leastone fungicide includes an azole, a strobilurin, a fludioxonil, or amixture thereof.
 6. The wall assembly of claim 1, wherein the coatingincludes at least three fungicides.
 7. The gypsum board of claim 6,wherein the at least three fungicides include a mixture ofthiabendazole, azoxystrobin, and fludioxonil.
 8. The wall assembly ofclaim 1, wherein the fungicides are present in the coating in an amountof from 1 ppm to 10,000 ppm.
 9. The wall assembly of claim 1, whereinthe pigment comprises a white pigment.
 10. The wall assembly of claim 1,wherein the pigment comprises calcium carbonate, magnesium carbonate, ora mixture thereof.
 11. The wall assembly of claim 10, wherein thepigment further comprises a titanium dioxide.
 12. The wall assembly ofclaim 1, wherein the pigment has a brightness of at least 90% asdetermined in accordance to T534 om-76 and/or a median size of from 0.1microns to 5 microns.
 13. The wall assembly of claim 1, wherein thepolymeric binder comprises a vinyl acetate polymer or copolymer, anacrylic polymer or copolymer, a styrene polymer or copolymer, a vinylacrylic polymer or copolymer, a cellulose, a starch, or a mixturethereof.
 14. The wall assembly of claim 1, wherein the polymeric bindercomprises an acrylic polymer or copolymer, a styrene acrylic copolymer,a styrene butadiene copolymer, a vinyl acrylic copolymer, or a mixturethereof.
 15. The wall assembly of claim 1, wherein the polymeric bindercomprises a mixture of an acrylic polymer or copolymer, a styrenebutadiene copolymer, and a cellulose.
 16. The wall assembly of claim 1,wherein the coating comprises a surfactant.
 17. The wall assembly ofclaim 1, wherein the coating comprises a wax.
 18. The gypsum board ofclaim 17, wherein the wax comprises a polyolefin wax.
 19. The wallassembly of claim 1, wherein the facing material comprises a paper. 20.A wall assembly comprising: a gypsum board comprising a gypsum corehaving a first side and a second side opposing the first side, at leastone facing material having a coating comprising at least one fungicide,at least one polymeric binder comprising an acrylic polymer orcopolymer, a styrene acrylic copolymer, a styrene butadiene copolymer, avinyl acrylic copolymer, or a mixture thereof, and at least one pigment,wherein the board exhibits at least a Level 3 finish, and wherein theboard satisfies at least one of the following: the board exhibits arating of 2 or less when tested in accordance to ASTM G21-15, or theboard exhibits a rating of at least 8 when tested in accordance to ASTMD3273-16.
 21. The wall assembly of claim 20, wherein the polymericbinder comprises a mixture of an acrylic polymer or copolymer and astyrene butadiene copolymer and further comprises a cellulose.